CA1282443C - Replacement flooring assembly for dump trucks or r.r. cars and method ofmaking - Google Patents

Abstract

ABSTRACT OF THE DISCLOSURE
The method of making a replacement flooring for a dump truck having a body upon a frame, the body including front and side walls and a flooring plate, comprising the steps of superimposing a metal replacement floor over the flooring plate, peripherally welding it thereto defining a sealed chamber between the plates. Further steps include drilling a vent and fill opening through the replacement plate, thereafter injecting under pressure a two-stage thermosetting copolymer filling the chamber and thereafter curing the copolymer providing a hardened spacer filler between the plates. Replacement flooring for the flooring plate comprises a replacement floor plate superimposed over the flooring plate and peripherally welded and sealed thereto defining a sealed chamber between the plates. A hardened cured filler spacer of a thermosetting copolymer material is snugly interposed between the plates.

Description

4~3 1430.005 REPLACEMENT FLOORING ASS~MBLY FOR
DUMP TRUCKS OR R.R. CARS AND METHOD OF MAKING SAME

Hereto~ore in the use of dump trucks including a tilt body or dump box having a pivotal tailgate, in railroad cars and off-road trucks, and the dropping of hard objects of metal and concre~e into said trucks, eYentually the flooring plate and sidewalls become damaged, distorted, bent, or fractured, requiring repair or replacement.

Heretofore in order to maintain the life of such flooring plates for dump trucks, railroad cars, and off-road trucks, it has been eommon to use a wood floor including a series of planks arranged side-by-side and mounted and seeured upon the floorirg plate and sidewalls or bolted thereto. mese are usually 2" by 6" or 2" by 8" to provide a protective surface for the dump truck metal flooring and sidewalls.

The wood overstructure absorbs shock and protects the steel flooring plate from damage for a considerable period of time. Under severe usage, eventually the wood flooring becomes darnaged or splintered and loses its protective character with respeet to the underlying floor plate. Continued use of the dump truck results in subsequent dsmage to the floor plate distorting, fracturing, or bending portions thereof.

Heretofore it has been conventional practice to replace the wood flooring as soon as considerable damage to the floor has been noticed. Normally, such replacement involves approximately $300 for lumber and another $200 in labor to provide a replacement protective wood flooring nonnally bolted or otherwise secured to the basic flooring plate. The wood flooring under ~evere use lasts for approximately one year before it must be replaced and new lumber reinstalled.
Often, when there is damage, distortion, bending, or fracture to the floor plate, it effects corresponding damage and cave-in o the sides of the dump truck body.
The tailgate does not close properly.

.82~3 1430.005 Without proper c~re and replacement of the wood flooring, the basic steel fl!oorin~ ultimately will be damaged, distorted, bent, or fractured to such an extent that its replacement is required at considerable expense. It is known to provide a reinforcement for the steel flooring of a dump truck and wherein overlying a hard wood flooring there is positioned and secured a second steel plate to overlie the wood flooring. This is an expensive procedure.

An important feature of the present invention is to provide a method of making a replacement ~looring for a durrp truck, a railroad car, or other truck and wherein the basic flooring plate has been damaged, fractured, bent or distorted. Another featllre is to proYide an auxiIiary flooring for the basic flooring plate to preYent damage thereto.

lt is another feature to provide a methcd of making a replacem~nt fiooring which eliminates the need for utilizing a replacement hard wood flooring and cost thereof.

An important feature is to provide for the damaged flooring plate of the dump truck, railroad car, or other truck with a replacement plate which is superimposed over the damaged flooring plate and periphera~ly welded thereto and wherein there is defined between the plates a sealed cha~er.

A further feature includes the step of drilling one or a pair of vent openings through the replacement plate adjacent one end thereof and adjacent its opposite end drilling a fill opening. A further step includes injecting under pressure through the fill opening through a suitable nozzle a quantity of liquid thermosetting copolyrner for filling the chamber betwesn the plates.

A further feature includes a $hermosetting copolymer selected from the group consisting of polyethylene, polyurethane, polypropylene, polystyrene and polycarbonate.

1430.005 A further step includes filling the chamber between the plates with the thermosetting copolymer under a predetermined pressure and thereafter plugging up the openings in the repIacement plate.

A final step ineludes curing the the~nosetting copolymer for a period of tirne sufficient for it to harden, thereby providing a spacer Iiller between the plates substRntially throughout their opposing surfaces in supporting engagement with the replacement plate, and to provide a cushion against further damage to the original floor. The sa~ method could be used to protect the basic flooring against darnage.

A further eature includes a replacement flooring for the damaged flooring plate of a dump truck, railroad car or other truck.

Another feature includes a replacement flooring wherein, after patching and repair of the darnaged flooring plate, the replacement steel plate is positioned over and is peripherally welded to underlying portions o the damaged flooring plate to define between the plates a sealed chamber. A hardened, cured filler spacer of a thesetting copolymer material is snugly interposed between the plates providing a protecffve support for the repl~cement plate and the old plate, preventing fur$her indentatios~s, puncturing or damage thereto.

A further feature as a part of the present method includes the preliminary step of patching or repairing the damaged flooring plate by welding thereto metallic patches to provide a sealed chamber between the respective plates when assernbled and peripherally secured, into which the liquid two-stage thermosetting copolymer is injected under pressure and confined within the chamber.

1430.005 Another feature is to provide a two-stage thermosetting copolymer which includes a suitable resin and polyisocyanate such as polyurethane which is initia~ly purnped or injected into said chamber having a viscosity of a gear lubeJ i.e. a viscosity 742, CP~.

Another feature, be~re injecting of the two-stage thennosetting copolymer, is arrangement of ~e assembled plates at an acute angle to the horizontal for controlling the average height of the hardened Iiller once cured.

Another feature is to provide a replacement or protective steel plate to which has been preattached a layer of a thermosetting copolymer. There the replacement or protective plate is mounted over and peripherally secured or welded to the fractured depressed flooring plate, or to an undarnaged flooring plate.

Another feature is to apply a layer of said copolymer over the fractured, depressed, or otherwise damaged floor plate, and after curing of the copolymer layer, applying and anchoring a series of hardened planks over the eopol~ner.

Another feature is to omit the planks and disperse within the resin ~ pulverized carbonate material and a marble dust, so tha~ when cured, the carbonate resists abrasion and the marble dust resists impact.

According to the invenffon, there is provided the method of making a replacement flooring for a dump truck having a body nested within and secured upon a skeleton frame, said body including side and front walls and a steel flooring plate, comprising the steps of:

loosely superimposing a replacement steel floor plate upon and overlying the top surface of the flooring plate in registry therewith;

~2~ 43 430.005 peripherally welding the replacement pl~te to underlying portions of the floor plate, defining a sealed chamber between said plates;

drilling through said replacement plate at least one ~rent opening and a fi~l opening;

injecting under pressure throu~h said fill opening into arld filling said charrber with a quantity of liquid thermosetting copolymer selected from the group consisting of polyethylene, polyurethane, polypropylene, polystyrene and polycarbcnate;

filling said ch~nber with said copolymer to a predetermined pressure;

plugging up the openings in said replacemen~ plate; and curing the thermosetting copolyrr~r for a period of time sufficient to provide a hardened spacer filler between said plates substantially throughout their opposing surfaces in supporting engagement with said replacement plate.

Further, according to the invention, there is provided a replacement flooring for a durlp truck having a body nes~ed within and secured upon a skeleton frame, said body including front and side walls and a flooring plate secured upon said fr~me;

comprising a replaeement flooring plate superilTposed over said flooring plate;

welds peripherally conneeting and sealing said floor plate to said ~looring plate, defining a sealed cha~er between said plates;

430~005 and a hardened cured filler spacer vf a thermosetting copolymer ~terial within and fi~ling said chan~er interposed between said plates substantially throughout their opposing surfaces, overlying said flooring plate and in supporting engagement with said replacement plate.

~ urther, according to the invention, there is provided a replacement flooring or a dump truck havlng a body nested within and secured upon a skeleton frame, said body including front and side walls and a flooring plate secured upon said frame;

a replacement floor plate of substantially the same shape as said nooring plate;

a layer of a cured hardened spacer of a thermosetting copolyrner n~terial adhered to the undersurface of said replacement lloor pl~te;

said repl2cement floor plate and layer of cured copolyrner material being mounted oYer and upon said floor plate in snug registry therewith;

and means peripherally ~onnecting said replacement floor plate to said flooring plate;

said layer of copolymer material being interposed between said plates substantially throughout their opposing surfaces and supporting said replacement plate against indentation and other damage.

Further, according to ~e invention, there is provided a replacement flooring for a dump truck having a body nested within and secured upon a skeleton frarne, said body including front and side walls and a flooring plate secured upon said frame;

-430.005 a layer of a cured hardened spacer of a thermosetting copolymer material overlying ~nd adhered to said flooring plate over its area and having aplanar top surface;

a replacemen~ flooring overlying said copolymer material including a plurality of hardwood planks arranged side by side and overlying said planar top surface;

and means securing said planks to said flooring plate.

These and other objects and ~eatures will be seen from ~e following speci~ication and claims in conjunction with the appended drawings.

Figure 1 is a schematic rear elevational view of a dwnp truck illustrating the present replacement flooring assembly or the damaged flooring plate OI a durnp truck body.

Figure 2 is a schematic plan view o the dump truck body, on a reduced scale, illustrative of the step OI injecting a two-stage thermosetting copolymer between the damaged flooring plate and the replacement plate, and the purnping apparatus.

Figure 3 is a sectional view thereof taken in the direction of arrows 3-3 of ~igure 2, illustrating the inclination of the floor plates during injection of the copolymer therebetween.

Figure 4 is a cross-sectional view corresponding to Figure 2 with the replacement plate unifor~y spaced from the d~maged plate.

_~_ ~2~2~43 .0as Figure 5 is a ~ragmentary end elevational view of one of the plurality of U-shaped tubular stiffener ribs forming a part of a skeleton frame of a dump truck with the base of the stiffeners filled with a hardened thermosetting copolyrner material.

Figure 6 is a fragmentary exploded view o~ a modified replacement flooring.

Figure 7 is a rear elevational view similar to Figure 1, showing a modified wood fLooring.

It is understood that the above drawings illustrate merely preferred embodiments OI the invention, and that other embodirnents ~re contemplated within the scope of the claims hereafter set forth.

Referring to the drawings, ~igures 1 through 4, a dwnp truck is schernatically illustrated at 11 in Figure 1 having a chassis 13 overlying and supported in a conventional manner upon a transverse axle 15 mounting the wheels 17.

The present dump truck includes a tilt body 19 as a conventional construction in the nature of a dump box with a pivotal tailgate, now shown, and wherein upon and Qlong and overlying the chassis 13 and suitably secured thereto are a series of longitudinally-spaeed upright U-shaped tubular ribs 21 defining a skeleton frame, Figure 2. The bases of the ribs~ normally flat, have been bent downwardly toward the center due to similar depression of the damaged flooring plate 23.

The tilt body 19 is nested within and secured upon the skeleton frurr.ework. In normal operation, and employing a hydraulic or pnelunatic telescoping piston rod 45, Figure 3, the tilt body 19 is adapted for tilting upwardly to a suitable acute angle sufficient for unloading.

1~30.005 In the illustrated embodirnent, the tilt hody includes front wall 33, fragmentarily shown in Figure l, and sidewa~, 27, which in the illustrated embodirnent are of 3/16th inch to 7/16th inch steel.

The respective sidewalls 27 at their lower ends terminate in the curved base portions 2') suitab1y connected to the steel fiooring plate 23, hereafter referred to as ~e damaged, distorted, bent, or fractured steel flooring plate which has one or a plurality of fractures 35, Figure 31.

The basic flooring plate 23, constillcted of 3/16th to 7/16th steel, as a part of body l9 is originally f~at and extends over the initia71y flat bottomed respective U-shaped tubular stiffener ribs 21 and is suitably secured thereto Q~3 by welds at 25, Figure 1. In mQny conYentional dump trucks, the ~looring plate 23 as darnaged is inclined from its sides inwardly and downwardly-defining a centerline 24 which extends longitudinally of the body.

As is a conventional construction, the basic flooring plate 23 and body 19 at its rearward end is pivotally hinged as at 37 to the chassis or îrarnework 13 of the dump truck and is adapted for pivotal adjusbn~nts such as to the 30 angle shown, for illustration in Figure 3. Tipping c,f body lf7 iS under the control of a hydraulic ~ift 39 of a conventional construction or other mechanical equivalent mechanism for elevating and tilting the body including the flooring plate 23 to the desired acute angle for dumping.

In the illustrative e~odiment, the hydraulic li ft includes a cylinder 41 pivotally mounted as at 43 upon the framework 13, Figure 3, and includes a reciprocal telescoping piston rod 45 which at its upper end is pivotally connected at 47 to the forward undersurface of body 19 and specifically to the flooring plate 23.

1430.005 In accordance with the present method, there is employed a rectangular replacement plate 49, preferably 3/16th" to 7/16th" steel which is cut so as to overlie the flooring plate 23, Figure 2, and is suitably secured thereto.

In the illustrative embodiment, the replacement noor plate 49 is peripherally welded at 25 to underlying ~urface porffons of flooring pla~e 23, thereby defining the sealed chamber 81.

In the illustrative embodiment disclosed in Figures 1 and 3, after considerable use and darnage, the conventional and original flooring plate 23 has opposite side portions inclined downwardly and inwardly at 24. This deEines a subs~antially triangular cross-section chan~er 81. ll-e ma~im~n height of chamber 81 ranges from 1/2" to 2", for illustration. This depends upon the extent of darnage to the original floor plate.

As a step in the method making a replacement flooring for the damaged dump truck flooring 2 3, after the replacement plate 49 has been peripherally welded in place Figures 1 and 2, one or a pair of air vents 53 are drilled through replacernent floor plate 49 adjacent one end. After use they are closed by the plugs 55. Single fill hole 47 is drilled through replacement floor plate 49 adiacent is other end and is adapted to receive a pressure fi~l nozzle 5g.
Said nozzle is arranged ~t one end of the pressure hose 61 connected by hose fitting 73 to pump easing 63.

The apparatus for injecting a thermosetting copolymer material into chamber 81 between the respective plates 23 and 49 includes within pump casing 63 storage container 65 for a liquid isocyanate or any of the other alternately usable thermosetting copolymers.

The copolymer employed is selected from the group which includes polyethylene, polyurethane, polypropylene, polystyrene, and polycarbonate.
In the illustrative ern~odiment, li~uid isocyanate is stored within container 65.

~X~X4~3 1430.0û5 Within an adjacent storage container 67 in casing 63 there is provided a suitable liquid resin material.

The isocyanate and resin within said containers are liquid and are pumped as by the pumps 69 and 75 irom the respective containers 65 and 67 through conduits 71 and 77 to hose fitting 73. By this assembly and during energization of pUlTpS 69 and 75 from a suitable power source as is conventional, a two-stage thermosetting copolymer such as polyurethane is pumped through hose 61, through the nozzle 59, ~nd through the filler opening 57 in plate 49 and into chamber 81.

In the illustrati~re embodirnent, and as one of the steps in the present method, injection of thermosetting copolymer is done with the assembled plates 23 and 49 tilted at an acute angle, as for example 30, Figure 3.

The angle at which the assembled and sealed plates 23 and 49 is tilted determines the approximate height of the filler mQ~erial 93 injected into sealed ch~er 81 between plates 23 and 49.

After the injection of the required amount of thermosetting copolymer into chamber 81, filler opening 57 is closed by the plug 79, shown in Figure 4, and the vent openings 53 are closed by plugs 55, Figure 2.

In the modified replacement floor assembly, Figure 4, the corresponding flooring plate 23 and the repIacement plate 49 define a sealed chamber 81 which is of uniform height throughout the perirneter. This is achieved by the employment of peripheral spacers 83, generally OI rectangular shape in cross-section which extend around the periphery of the respective plates 23 and 49 and are welded thereto as at 85. There still may be some angular depression of the damaged flooring plate 23.

1430.0U5 As a final step, the thermosetting copolymer material is cured by permitting it to stand for a period of time sufficient that the copolymer ma$erial hardens to provide a filler spacer 93, Figure 4. The hardened filler spacer is snugly interposed between plates 23 and 49 in registry with their adjacent surfaces and bears upon floor plate 23. Said plate was patched at 50, Figure 3, for illustration, with the patches welded in place.

In the i11ustrative embodiment, the two-stage thermosetting copolymer material, including the resin, has a viscosity of gear lube, identified as viscosity 742, CPS, for illustration. After curing, the filler spacer 93 has a hardness 57 on a shore D gauge.

In the modification shown in Figure 5, one of a plura1ity of longitudinally-spaced, upright, U-shaped tubular sti~fener ribs 21 is shown which includes side chambers 87 and the horizontal bottom chamber 89. Utilizing a suitable fill hole 91~ subsequently plugable as by the plug 55 shown in ~igure 2, thermosetffng copolymer 93 is iniected into the respective stiffener ribs 21 ~orming a part of the framework, using the apparatus of Figure 2. Each of the ribs are filled in accordance with the present method. The injected thermosetting copolyml3r filling 93 within bottom chamber 89 is cured and hardened over a sufficient time, between one and four hours, for illustration.

By the construction shown in Figure 5, the basic flooring plate 23 and the replacement plate 49 overlie a series of longitudinally-spaced, U-shaped upright tubular stiffeners 21 and are suitably secured thereto as by welds at 25.

- In accordance with the present disclosure a thermosetting copolymer resin material selected from the group of copolymers above listed is injected in liquid form into said tubular ribs and after curing provides a hardened interior reinforcement for the bases of me corresponding stiffener ribs. Ihe ribs 1430.005 so reinfor¢ed will not deflect due to the interior fi11er spacer reinforcement therein and thus prosride a better supporting surface for flooring p~ate 23.

~ panning the spaces between the respective spaced ribs 21 are unsupported portions ~r flooring 23 applied thereto. The present replacement method, as above described with respect to ~igures 1, 2, and 3, could be applied for the replacement floor assembly shown in Figure 5.

The pr~nary purpose o~ th~ illustra~ion in Figllre 5 is to show a means by which the present two-stage thermQsetffng copolymer materials CRn be injected into base portions of the respective tubular stiffeners forming a part of the dump truck framework.

"
In reference to the flooring plate of a dump truck, it is regarded as equivalent that such plate be the flooring plate of any othsr trucks or a railroad car.

The present method of making a replacement flooring for a dump truck having a tilt body l9 nested within and secured upon a skeleton frame 21, said body including sidewalls 27, front wall 33, and a damaged, distorted, bent or fractured steel flooring plate 23~ includes the following steps:

1. Loosely superirn~osing a replacement steel floor plate 49 upon and overlying the top surface of the damaged ~looring plate 23 having breaks or indentations designated at 35, ~igure 3;

2. Peripherally weMing, as at 25, replacement plate 49 to underlying por~dons of the damaged floor plate 23, defining a sealed chamber 81, Figures 3 and 4;

3. drilling at 53 through replacement plate 49 one or more apertures or vents and successively drilling a fjll opening 57, ~igure 2;
~13--~,2~f~443~

1430.005 4. iniecting, under pressure, a liquid mixture of a eopolymer and resin 69, 75 through pipe 61 and nozzle 59 ~hrough ~e fill opening 57 and into the chamber 81, i.e., a quantity of liquid thelmosetting copolymer 93. Since ~ large nurr~er of copolymers are available, ~he liquid the~nosetting copolymer is selected from the group consisting of polyethylene, polyurethane, polypropylene, polystyrene, and polycarbonate and where in the preferred embodiment a polyisocyanate is employed with a resin for producing polyurethane;

S~ under the operation of the respec~ive pwnps 69 and 75 connected to the storage container 65, for the liquid isocyanate and the storage container 67 for the liquid resin at 67, respectively liquid ingredients are delivered through fitting 73, conduit 61 and nozzle 59 under pressure into chamber 81 for filling the ~harrber with the thermosetting copolymer material;

6. plugging up ~he openings as by the plugs 55 and 79, Figures 2 and 4, to seal off chamber 81; and 7. curing the the~nosetting copolymer for a period of time sufficient to provide a hardened spacer filler 93 between the plates 23 and 49, essentially throughout their opposing surfaces, in supporting engagement with replacement plate 49. In the illustrative embodiment, - the curing time is in the range of one to four hours.

Where needed in ~e case where the basic ~looring plate 23 has been fractured, there is the prelirninary step of repairing and patching as at 50 the respective perforations 35, Figure 3, using suitable 3/16" steel patches welded in place. This is to assure that the chamber 81 defined between the plates 23 and 49 is properly sealed and to prevent escape of the pressurized thermosetting copolyrner before it has cured and hardened.

2~43 1430.005 The liquid thermosetting copolymer, as delivered by nozzle 59, has a gear lube viscosity 741, approx~mately. The polyurethane, as pumped through the nozzle 59 is a two-stage material which includes a liquid resin and one of the identified copolymers such as liquid polyisocyanate.

As a îurther step or an additional step as defined in Figure 5, the skeleton frame îor the dump truck, as is con~entional, has a series o~
longitudinally-spaced, upright, U-shaped tubular stiffener ribs 21 which normally have top rails as a part thereof which extend between the respective stiffener ribs. Often there is an intermediate side reinforcing rail connecting the respective ribs to make up the skeleton framework within which is nested the tilt body 1~ Ior the dump truck.

A further step, in accordance wi~h the present method, includes injecting under pressure a quantity of said liguid thermosetting copolymer through the fill hole 91 (thereafter plugged as at 55, Figure 2) as at 93 for filling the bottom chambeI 89 of the respective stiffeners 21. The side portions of the stiffeners at 87 need not be filled with the particular copolymer.

A ~urther step includes the curing o~ the ~ermosetting copolyrner as at 93 for a period up to three hours, ~or iIlustration, to provide a hardened reinforcing support within the base portion of each of the stiffeners.

In the present method, there is the intermediate step before injection of the copolymer between the pl~es, as shown in Figure 3, namely tilting the plates 23, 49 at an acute angle to the horizontal, as for example at 30~. This angle can be changed to vary the depth of the copolymer material injected within sealed cham~er 81.

A modified replacement flooring 97 for a dwnp truck or a railroad car or other truck is fragrnentarily disclosed in Figure 6, and wherein upon ~ ~3Z~'lL3 430.00S
the conventional series of longitudinally-spaced stiffener ribs 21 of tubular form9 there is the conventional flooring plate 23 above described which spans the ribsand is secured thereto as by welding at 25.

Where the original flooring plate 23 has been darnaged or bent or indented, as above described and shown in ~igure 1, a n~dified replacement flooring 97 includes replacement steel plate 49. To the plate upon its undersurface has been preattached at ~4 a layer 93 of the present therm~setting copolymer.

Once the copolymer sheet 93 has been cured upon the replacement plate 49, it may be separately applied to an existing damaged flooring plate 23. Plate 49 is shown spaced above plate 23. l'he repl~cement flooring plate, including the epo2~y layer 93, is lowered onto the damaged flooring plate 25 and is suitably secured thereto peripherally ~s by welding or otherwise, such as by bolts.

In the illustrative embodiment, Figure 6, relating to the preattachment of a copolymer to the sheet of steel 49, there may be employed an expanded metal grating 99 within the copolyrner as an additional reinforcement.
This application may be applied to ~e damaged flooring of a railroad car or any off-road truck as well as dump truek.

A modified flooring replacement is shown schematically at 101, Figure 7, similar to the designation of the durnp truck in Figure 1. Upon the damaged and depressed basic flooring plate 23 there is applied a layer of the a~ove-described thermosetting copolymer at 93. After the copolymer has been cured, taking the form shown in ~igure 7, tl ere is applied thereto a wood flooring 103 consisting of a series of laterally aligned, longitudinally-extending hardwood planks suitably secured as at 105 to the underlying flooring plate 23.

1430.005 Figure 7 illustrates a modification of the present invention and wherein with less expense, instead of employing a replacem~nt steel plate as at 49, Figure l, upon the cured epoxy layer 93, which has becom~ hardened, there is applied a replacement wood flooring 103. This, therefore, provides a more economical flooring replacement than abo~e-described with respect to Figure 1 and under some conditions mEIy be useful.

It is contemplated that the present method and flooring may be Qpplied to undamaged flooring OI a dump truck, rai~road car, and other trucks.
This is for the purpose of reinforcing, strengthening and protecting the basic Iloor against impact damage, wear and erosion.

The present method is the same except that it is unnecessary to make any repairs to the basic flooring before application of the secondary protective flooring shown in the drawings, Figures 1-7.

The present modified method of tr~king a protective flooring for the fl~or of a dump truck having a body 19 nested within and secured upon a skeleton frame 21, wherein said body includes sidewalls 27, front wall 33, and a steel flooring plate 23, includes the Iollowing steps:

l~ Loosely superimposing protective steel floor plate 49 upon and overlying the top surface of flooring plate 23, Figure 3;

2. peripheral1y welding as at 25 supplemental plate 49 to underlying portions of floor plate 23 defining a sealed chamber 81, Figures 3 and 4;

3. dri~ling at 53 through plate 49 one or more apertures or vents and successively drilling a fill opening 573 ~igure 2;

~Xf~X~43 1430.005 4. injecting, under pressure, a liquid mixture of a copolymer and resin 69, 75 through pipe 61 and nozzle 59 through the fill opening 57 and into chamber 8l, a ~uantity of liguid thelmosetting copolyrner 93.
~ince a large nurnber of copolymers are available, ~he liquid thermosetting copolymer is selected from the group consisting of polyethylene, polyurethane, polypropylene, polystyrene, and polycarbonate. In the preferred embodiment, ~ polyisocyanate is employed with a resfn for producing polyurethane;

5. under the operation of the respective pwnps 69 and 75 connected to storage container 65 for the liquid resin at 67, the respectively liquid ingredients are delivered through fitting ~3, conduit 61 and nozzle 59 under pressure into chamber 81 for filling the chamber with the the~nosetting copolymer material;

6. plugging up the openings by plugs 55 and 79, Figures 2 and 49 to seal off chamber 81; and 7. curing the thelmosetting copolymer for a period of time sufficient to provide a hardened spacer filler 93 between ~e pl~tes 23 and 49 essentially throughout their opposing surfaces in supporting engagement with plate 49. In the i11ustrative embod~nent, the curing time is in the range of one to four hours.

With respect to Figure 5, plate 49 may be a supplemental or protective plate. Flooring plate 23 need not be damaged and n~y be flat.

In Flgure 6, flooring 97 rnay be a protective flooring for a conventional, undamaged flooring plate 23. Protective plate 49, with a cured copolymer sheet 93 thereon, overlies undamaged ~loor plate 23 and is secured thereto.

1430.005 In the ~ dification 101, Figure 7, the protective assembly 103 may be applied to and secured over an undamaged floor plate 23. Here, upo~
flooring plate 23, which may be Ilat, there is applied a layer of said therm~setting copolymer at 93. After curing of the copolymer, wood flooring 103 is applied over the cured copolyrner and secured thereto.

As a further modification of Figure 7, planks 103 are on~itted.
The epoxy layer 93 is modified by adding and dispersing within the liquid resin:

1. A pulverized carbonate material such as polycarbonate crystals.

2. A marble dust or pulverized mQrble. When the nn2~ed copolyrner is set and hardened, the carbonate resists abrasion and the marble resists impact.

Claims (27)

1. The method of making a replacement flooring far a dump truck having a body nested within and secured upon a skeleton frame, said body including side and front walls and a steel flooring plate, comprising the steps of:
1. loosely superimposing a replacement steel floor plate upon and overlying the top surface of the flooring plate in registry therewith;

2. peripherally welding the replacement plate to underlying portions of the floor plate, defining a sealed chamber between said plates;

3. drilling through said replacement plate at least one vent opening and a fill opening;

4. injecting under pressure through said fill opening into and filling said chamber with a quantity of liquid thermosetting copolymer selected from the group consisting of polyethylene, polyurethane, polypropylene, polystyrene and polycarbonate;

5. filling said chamber with said copolymer to a predetermined pressure;

6. plugging up the openings in said replacement plate; and

7. curing the thermosetting copolymer for a period of time sufficient to provide a hardened spacer filler between said plates substantially throughout their opposing surfaces in supporting engagement with said replacement plate.

2. In the method of making a replacement flooring of claim 1, the intermediate step of locating said openings adjacent opposite ends of said replacement plate.

3. In the method of claim 1, said floor plate being damaged, distorted, bent or fractured, including the preliminary step of repairing and patching all apertures in said damaged flooring plate.

1430.005 4. In the method of claim 3, said repairing including welding metal patches over and spanning said apertures.

5. In the method of claim 1, said liquid thermosetting copolymer having a gear lube viscosity of 742 CPS approximately.

6. In the method of claim 1, said copolymer being polyurethane.

7. In the method of claim 1, said injecting of said copolymer including simultaneously pumping through a nozzle a two-stage material including a liquid resin and a liquid isocyanate.

8. In the method of claim 1, said curing time being one to four hours.

9. In the method of claim 1, said skeleton frame for the dump truck body including a series of upright, U-shaped tubular stiffener ribs; the further step of injecting under pressure a quantity of said liquid thermosetting copolymer filling the base of each stiffener; and curing the thermosetting copolymer in said stiffeners for a period of up to three hours to provide a hardened reinforcing support therein.

10. In the method of claim 1, the intermediate step of inclining the assembled plates at an acute angle to the horizontal before injecting the copolymer.

11. In the method of claim 1, the preliminary step before welding of spacing the replacement plate from the flooring plate.

12. In the method of claim 1, said filler hardness being 57, approximately on a Shore D gauge.

1430.005

13. A replacement flooring for a dump truck having a body nested within and secured upon a skeleton frame, said body including front and side walls and a flooring plate secured upon said frame;
comprising a replacement floor plate superimposed over said flooring plate;
welds peripherally connecting and sealing said floor plate to said flooring plate, defining a sealed chamber between said plates;
and a hardened cured filler spacer of a thermosetting copolymer material within and filling said chamber interposed between said plates substantially throughout their opposing surfaces, overlying said flooring plate and in supporting engagement with said replacement plate.

14. In the replacement flooring of claim 13, said thermosetting copolymer being selected from the group consisting of polyethylene, polyurethane, polypropylene, polystyrene, and polycarbonate.

15. In the replacement flooring of claim 13, said floor plate being damaged, distorted, bent or fractured, a plurality of spaced patches overlying and welded to the fractured flooring plate for sealing off said chamber.

16. In the replacement flooring of claim 13, said flooring plate being inclined downwardly and inwardly from its outer sides to a centerline, said chamber having a maximum height along said centerline between 1/2 and 3 inches.

17. In the replacement flooring of claim 13, said copolymer filler spaced including a resin and an isocyanate.

18. In the replacement flooring of claim 13, said frame including a series of spaced, upright, U-shaped tubular stiffener ribs; and a hardened thermosetting copolymer filling the base portion of said stiffeners as a reinforcement therefor.

1430.005

19. In the replacement flooring of claim 13, a continuous peripheral spacer of rectangular cross-section interposed between opposed peripheral portions of said plates and welded thereto, whereby said chamber and said spacer filler are of uniform height.

20. A replacement flooring for a dump truck having a body nested within and secured upon a skeleton frame, said body including front and side walls and a flooring plate secured upon said frame;
a replacement floor plate of substantially the same shape as said flooring plate;
a layer of a cured hardened spacer of a thermosetting copolymer material adhered to the undersurface of said replacement floor plate;
said replacement floor plate and layer of cured copolymer material being mounted over and upon said flooring plate in snug registry therewith;
and means peripherally connecting said replacement floor plate to said flooring plate;
said layer of copolymer material being interposed between said plates substantially throughout their opposing surfaces and supporting said replacement floor plate against indentation and other damage.

21. In the replacement flooring of claim 20, said thermosetting copolymer being selected from the group consisting of polyethylene, polyurethane, polypropylene, polystyrene, and polycarbonate.

22. In the replacement flooring of claim 20, said copolymer filler spacer including a resin and an isocyanate.

23. In the replacement flooring of claim 20, an expanded metal grating set within said layer of copolymer material as a reinforcement therefor.

1430.005

24. A replacement flooring for a dump truck having a body nested within and secured upon a skeleton frame, said body including front and side walls and a flooring plate secured upon said frame;
a layer of a cured hardened spacer of a thermosetting copolymer material overlying and adhered to said flooring plate over its area and having a planar top surface;
a replacement flooring overlying said copolymer material including a plurality of hardwood planks arranged side-by-side and overlying said planar top surface;
and means securing said planks to said flooring plate.

25. In the replacement flooring of claim 24, said thermosetting copolymer being selected from the group consisting of polyethylene, polyurethane, polypropylene, polystyrene, and polycarbonate.

26. In the replacement flooring of claim 24, said copolymer filler spacer including a resin and an isocyanate.

27. A replacement flooring for a dump truck having a body nested within and secured upon a skeleton frame, said body including front and side walls and a flooring plate secured upon said frame;
a layer of a cured, hardened spacer of a thermosetting copolymer material overlying and adhered to said flooring plate over its area and having a planar top surface;
said copolymer filler spacer including a resin, and said copolymer being selected from the group consisting of polyethylene, polyurethane, polypropylene, polystyrene, and polycarbonate;
a pulverized carbonate and marbled dust dispersed and mixed within the resin, on curing of the filler, said carbonate resisting abrasion and said marble dust resisting impact.